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GAS-FIRED WATER HEATER

A Spanish language version of these instructions is available by contacting


the company listed on the rating plate.
La version espanola de estas instrucciones se puede obtener al escribirle
a la fabrica cuyo nombre aparece en la placa de especificaciones.

INSTALLATION & OPERATING INSTRUCTION


MANUAL For Flammable Vapor Ignition Resistant
System Equipped Water Heater
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death.

FOR YOUR SAFETY


Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a neighbors
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
For your familys comfort, safety and convenience, we
recommend this water heater be installed and serviced by a
plumbing professional.

238-44219-00K REV 6/12

CONGRATULATIONS!
You have just purchased one of the finest water heaters on the market
today!
This installation, operation and instruction manual will explain in detail
the installation and maintenance of your new Flammable Vapor Ignition
Resistant Gas Water Heater. We strongly recommend that you contact a
plumbing professional for the installation of this water heater.
We require that you carefully read this manual, as well as the enclosed
warranty, and refer to it when questions arise. If you have any specific
questions concerning your warranty, please consult the plumbing
professional from whom your water heater was purchased. For your
records we recommend that you write the model, serial number and
installation date of your water heater in the maintenance section in the
back of this manual.
This manual should be kept with the water heater.
Special Flammable Vapor Ignition Resistant System:
This water heater is equipped with a Flammable Vapor Ignition Resistant System.
In the event of improper usage or storage of gasoline or other flammable materials
in the location where the water heater is installed, the technology will resist ignition
of the flammable vapors outside the confines of the water heater.
The Flammable Vapor Ignition Resistant System features:
Advanced Flame Arrestor Design.
Re-settable Thermal Switch to prevent burner/pilot operation with
restricted airflow.
Piezo Igniter
Sight Window to observe operation of pilot and burner.
FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant
System occurs when flammable vapors are drawn into the water heater and are
combusted. If flammable vapors are detected:
Do not try to light any appliance.
Do not touch any electrical switch; Do not use any phone in your building.
Leave the premises and immediately call the fire department from a
neighbors phone. Follow the fire departments instructions.
Once the flammable vapor has been evacuated, contact your plumbing
professional or the manufacturer for further instructions. Replacement of a
Flammable Vapor Ignition Resistant System equipped water heater due to a
flammable vapor shutdown is not covered under the terms of the limited warranty.

TABLE OF CONTENTS
GENERAL INFORMATION ............................................................

page
4

INSTALLATION .............................................................................

Locating the Water Heater .....................................................

Minimum Clearances ..............................................................

Venting.....................................................................................

10

Combustion Air Supply ..........................................................

11

Water Connections .................................................................

13

Gas Connections ....................................................................

16

GENERAL OPERATION ................................................................

17

Lighting and Shutdown Instructions ....................................

18

Thermostat Adjustment .........................................................

20

Burner Flame Check ...............................................................

22

MAINTENANCE .............................................................................

23

TROUBLESHOOTING ...................................................................

26

INSTALLATION DRAWING FOR POTABLE WATER ..................

28

PARTS LIST DRAWING ................................................................

29

PARTS LIST ...................................................................................

30

INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND


SPACE HEATING ..........................................................................

31

NOTES ...........................................................................................

32

GENERAL INFORMATION
This gas-fired water heater is design certified by CSA International under the
applicable American National Standard, Z21.10.1 or CSA 4.1-(as indicated on
the rating plate), available from CSA International, 8501 East Pleasant Valley
Road, Cleveland, OH U.S.A. 44131-5575.
This water heater must be installed in accordance with local codes. In the
absence of local codes, it must be inst0alled in compliance with the National
Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1
Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane
Installation Code (Latest Edition). The warranty for this water heater is in
effect only when the water heater is installed, adjusted, and operated in
accordance with these Installation and Operating Instructions. The
manufacturer will not be liable for any damage resulting from alteration and/or
failure to comply with these instructions.
This water heater is not design certified for installation in a mobile home.
Such an installation may create a hazardous condition and will nullify the
warranty.
This water heater has been designed and certified for the purpose of heating
potable water. The installation and use of this water heater for any purpose
other than the heating of potable water may cause damage to the water
heater, create a hazardous condition, and nullify the warranty.

CAUTION
Incorrect operation of this appliance may create a hazard to life and property
and will nullify the warranty.
Do not use this appliance if any part has been submerged in water.
Immediately call a qualified service technician to inspect the appliance and to
replace any part of the control system and any gas control, which has been
under water. Depending upon the individual circumstances, it may be
necessary to replace the entire water heater.

DANGER
Do not store or use gasoline or other flammable, combustible, or
corrosive vapors and liquids in the vicinity of this or any other
appliance.

General Information continued-

IMPORTANT
Before proceeding, please inspect the water heater and components for
possible damage. DO NOT install any damaged components. If damage
is evident then please contact the supplier where the water heater was
purchased or the manufacturer listed on the rating plate for replacement
parts.
This water heater has been manufactured for operation at altitudes from sea
level to 2000 feet (610 m) (unless otherwise specified on the water heater
rating plate). For use of this appliance at an elevation greater than 2000 feet
(610 m), contact the dealer or manufacturer listed on the rating plate for
information on any necessary modification. Uncorrected operation of this
appliance may create a hazard to life and property.
Make sure that you check the rating plate and combination gas control on the
water heater to be certain that the type of gas being supplied corresponds
with the marking on the rating plate and combination gas control.
A sacrificial anode is used to extend tank life. The removal of this anode, for
any reason, will nullify the warranty. In areas where water is unusually active,
an odor may occur at the hot water faucet due to a reaction between the
sacrificial anode and the impurities in the water. If this should happen, an
alternative anode may be purchased from the supplier that installed this water
heater. This will minimize the odor while protecting the tank. Additionally, the
water heater should be flushed with appropriate dissolvers to eliminate any
bacteria.

INSTALLATION
LOCATING THE WATER HEATER

WARNING
Water heaters are heat producing appliances. To avoid damage or injury
there must be no materials stored against the water heater or vent-air
intake system and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater and vent-air intake
components. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR
STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR
INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE WATER HEATER OR VENT-AIR INTAKE
SYSTEM.
This water heater MUST NOT be installed in any location where gasoline
or flammable vapors are likely to be present, unless the installation is
such to eliminate the probable ignition of gasoline or flammable vapors.
Water heaters in residential garages must be installed and located, or
protected, to avoid physical damage. For other installations refer to
local codes. In the absence of local codes, the water heater must be
installed in compliance with the National Fuel Gas Code, (ANSI Z223.1Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation
Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code
(Latest Edition).
The location of this water heater is of the utmost importance. Before installing
this water heater read the Installation section of these instructions. After
reading these Installation and Operating Instructions, select a location for the
water heater where the floor is level and is easily accessible to gas and water
supply lines. DO NOT locate the water heater where water lines could be
subjected to freezing temperatures. Make sure the cold water pipes are
not located directly above the gas control so that condensate during
humid weather does not drip on the controls.
This water heater MUST be installed indoors out of the wind and
weather.
To comply with NSF requirements this water heater is to be:
a) Sealed to the floor with sealant, in a smooth and easily cleanable
way, or
b) Installed with an optional leg kit that includes legs and/or extensions
that provide a minimum clearance of 6 beneath the water heater.

Installation (Locating The Water Heater) continued-

Note: For California installation this water heater must be braced,


anchored, or strapped to avoid falling or moving during an earthquake.
See instructions for correct installation procedures. Instructions may be
obtained from DSA Headquarters Office, 1102 Q Street, Suite 5100,
Sacramento, CA 95811.
Water heater corrosion and component failure can be caused by the heating
and breakdown of airborne chemical vapors. Examples of some typical
compounds that are potentially corrosive are: spray can propellants, cleaning
solvents, refrigerator and air conditioning refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes and process chemicals.
These materials are corrosive at very low concentration levels with little or no
odor to reveal their presence. NOTE: DAMAGE TO THE WATER HEATER
CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED
BY THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF
EXPOSURE HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY
CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

WARNING
Liquefied petroleum gases/propane gases are heavier than air and will
remain at floor level if there is a leak. Basements, crawl spaces, closets
and areas below ground level will serve as pockets for accumulation of
leaking gas. Before lighting, smell all around the appliance area for gas.
Be sure to smell next to the floor.
IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric switch; do not use any telephone in
your building.
Immediately call your gas supplier from a neighbors telephone.
Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

Installation (Locating The Water Heater) continued-

WARNING
Liquefied petroleum gases/propane gases are heavier than air and will
remain at floor level if there is a leak. Basements, crawl spaces, closets
and areas below ground level will serve as pockets for accumulation of
leaking gas. Before lighting, smell all around the appliance area for gas.
Be sure to smell next to the floor.
IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric switch; do not use any telephone in
your building.
Immediately call your gas supplier from a neighbors telephone.
Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!
Proper venting practices must be considered when selecting a location for this
water heater. For exact venting specifications, please consult the Venting
section of these Installation and Operating Instructions.
This water heater must be located in an area where leakage of the tank, water
line connections, or the combination temperature and pressure relief valve will
not result in damage to the area adjacent to the water heater or to lower floors
of the structure. When such locations cannot be avoided, a suitable drain pan
must be installed under the water heater. The drain pan must have a
minimum length and width of at least 4 inches (10.2 cm) greater than the
diameter of the water heater and must not restrict proper combustion air flow
to the water heater. The drain pan, as described above, can be purchased
from your plumbing professional. The drain pan must be piped to an
adequate drain. The piping must be at least inch (1.9 cm) in diameter and
pitched for proper drainage.
It is recommended that a minimum clearance of 4 inches (10.2 cm) be
provided on the side of the water heater for servicing and maintenance of the
combination temperature and pressure relief valve.

MINIMUM CLEARANCES

WARNING
Failure to adhere to these installation and operating instructions may
create a hazard to life and property and will nullify the warranty.
This installation must allow access to the front of the water heater and
adequate clearance must be provided for servicing and operating this water
heater. The water heater may be installed on either a combustible or noncombustible floor. If the water heater is to be installed directly on carpeting, it
shall be installed on top of a metal or wood panel (or equivalent) extending
beyond the full width and depth of the appliance by at least 3 inches (7.6 cm)
in any direction or, if the appliance is to be installed in an alcove or closet, the
entire floor shall be covered by the panel. If the rating plate or the label on
the front of the heater specifies minimum clearances less than those
listed in the below table, the water heater may be installed in accordance
with the minimum clearances listed on the rating plate or the label on
the front of the heater.
If it is necessary to install this water heater in an alcove, use the clearances
listed in Figure 1, increased distances provide greater clearances for
servicing.

Figure 1
9

VENTING

WARNING
The venting system must be installed properly following all local codes or in
the absence of local codes, the latest edition of the National Fuel Gas Code
(ANSI Z223.1-latest edition), or in Canada, The Natural Gas and Propane
Installation Code (B149.1-00 latest edition). Failure to properly install the
venting system could result in property damage, personal injury, or death.

WARNING
Carefully inspect the venting system of a replacement water heater
installation before connecting to the venting system. All joints in the vent
connector must be securely fastened with screws and fit tightly together.
Inspect the venting system for signs of deterioration (rust and perforation)
and replace any sections that are not in good condition.
The chimney must be lined and in good condition. Check to make sure
the venting system is properly sized for the water heater. If the venting
system was previously sized for another gas appliance that has been
removed, the venting system may now be too large. Refer to the latest
edition of the National Fuel Gas Code (ANSI Z223.1-latest edition), or in
Canada, the Natural Gas and Propane Installation Code (B149.1-00 latest
edition) for the correct sizing of venting systems and common venting with
another gas appliance.
Do not vent this water heater into the venting system of another gas
appliance designed to vent under positive pressure.
The water heater should be installed as close as practical to the venting
system to minimize the vent connector length required. Refer to local
codes for the distance limitations on vent connector lengths.
At the completion of the water heater installation, the burner and venting
system must be checked for proper operation with all other commonly
vented appliances in operation. Check for spillage of flue products
around the outside relief opening of the drafthood after several minutes of
operation. The flame from a match should be drawn into the drafthood.
Do not use the water heater or connected equipment if spillage is
detected until the problem is corrected. Refer to the latest edition of the
National Fuel Gas Code, or in Canada, the Natural Gas and Propane
Installation Code for complete details on the Procedure to Be Followed to
Place Equipment in Operation.
This water heater has been shipped with a draft diverter for which it was
designed with reference to the horizontal and vertical planes. If removed, the
draft diverter must be replaced in the same position and secured to the jacket
top by the screws with which it was installed.
10

Venting continued-

This water heater must be connected to a lined masonry chimney or venting


system approved by local codes or ordinances. The vent connector used to
attach the draft diverter outlet to the chimney or approved vent must be of the
same diameter as the draft diverter outlet or larger. For proper venting in
certain installations, a larger vent connector may be needed. Consult venting
tables in ANSI standard (Z223.1-or latest edition), National Fuel Gas Code
and CAN/CGA (B149.1 or B149.2-latest editions) Natural Gas and Propane
Installation Code, or local code officials for proper application for your area.

Combustion Air Supply

WARNING
Liquefied petroleum gases/propane gas are heavier than air and will
remain at floor level if there is a leak. Basements, crawl spaces, closets
and areas below ground level will serve as pockets for accumulation of
leaking gas. Before lighting, smell all around the appliance area for gas.
Be sure to smell next to the floor.
IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric switch; do not use any telephone in your
building.
Immediately call your gas supplier from a neighbors telephone.
Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

IMPORTANT
The flow of combustion and ventilating air must not be obstructed.
Do not block or in any way restrict jacket air inlet slots located at the
bottom front of the water heater.
Provide adequate air for combustion and ventilation. An insufficient supply of
air will cause recirculation of combustion products resulting in air
contamination that may be hazardous to life. Such a condition often will result
in a yellow, luminous burner flame, causing carboning or sooting of the
combustion chamber, burners and flue tubes with possible damage to the
water heater.
When an exhaust fan is installed in the same room with a heater, sufficient
openings for air must be provided in the walls. Undersized openings will
cause air to be drawn into the room through the chimney, causing
recirculation of combustion products.
11

Combustion Air Supply continued-

Confined Spaces
Confined spaces are spaces defined as having less than 50 feet (1.41 m) of
space per 1,000 BTU (.29kw) per hour of input.
Unconfined Spaces
In unconfined spaces in buildings, infiltration may be adequate to provide air
for combustion, ventilation and dilution of flue gases. However, in buildings of
tight construction (for example, weather stripping, heavily insulated, caulked,
vapor barrier, etc.), additional air may need to be provided using the methods
described above under CONFINED SPACES: All Air From Outdoors or
SPECIALLY ENGINEERED INSTALLATIONS.
All Air From Inside the Building: The confined space shall be provided with
two permanent openings communicating directly with an additional room(s) of
sufficient volume so that the combined volume of all spaces meets the criteria
for an unconfined space. The total input of all gas utilization equipment
installed in the combined space shall be considered in making this
determination. Each opening shall have a minimum free area of 1 inch (6.45
cm) per 1000 BTU (.29 kw) per hour of the total input rating of all gas
utilization equipment in the confined space, but not less than 100 square
inches (645 cm). One opening shall be within 12 inches (31 cm) of the top
and one within 12 inches (31 cm) of the bottom of the enclosure.
All Air From Outdoors: The confined space shall be provided with two
permanent openings, one commencing within 12 inches (31 cm) of the top
and one commencing within 12 inches (31 cm) from the bottom of the
enclosure. The openings shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall have
a minimum free area of 1 inch (6.45 cm) per 4000 BTU (1.2 kw) per hour
of total input rating of all equipment in the enclosure.
2. When communicating with the outdoors through vertical ducts, each
opening shall have a minimum free area of 1 inch (6.45 cm) per 4000
BTU (1.2 kw) per hour of total input rating of all equipment in the
enclosure.
3. When communicating with the outdoors through horizontal ducts, each
opening shall have a minimum free area of 1 inch (6.45 cm) per 2000
BTU (.6 kw) per hour of total input rating of all equipment in the enclosure.
4. When ducts are used, they shall be of the same cross-sectional area as
the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches (7.5
cm).
Specially Engineered Installations
The requirements noted under CONFINED SPACES above shall not
necessarily govern when special engineering, approved by the authority
having jurisdiction, provides an adequate supply of air for combustion,
ventilation, and dilution of flue gases.
12

WATER CONNECTIONS
Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE
MAIN WATER SUPPLY VALVE.
After shutting off the main water supply, open a faucet to relieve the water line
pressure to prevent any water from leaking out of the pipes while making the
water connections to the water heater. After the pressure has been relieved,
close the faucet. The COLD water inlet and HOT water outlet are identified on
the top of the water heater. The fittings at the cold water inlet and hot water
outlet are dielectric waterway fittings with inch NPT male thread. Make the
proper plumbing connections between the water heater and the plumbing
system to the house. Install a shut-off valve in the cold water supply line.

CAUTION
If sweat fittings are to be use, DO NOT apply heat to the nipples on top of
the water heater. Sweat the tubing to the adapter before fitting the adapter
to the water connections. It is imperative that heat is not applied to the
nipples containing a plastic liner.

WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED INCH X
INCH TEMPERATURE AND PRESSURE RELIEF VALVE WILL
RELEASE THE MANUFACTURER FROM ANY CLAIM, WHICH MIGHT
RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.

If this water heater is installed in a closed water supply system, such as the
one having a back-flow preventer in the cold water supply, provisions shall be
made to control thermal expansion. DO NOT operate this water heater in a
closed system without provisions for controlling thermal expansion. Your
water supplier or local plumbing inspector should be contacted on how to
control this situation
After installation of the water lines, open the main water supply valve and fill
the water heater. While the water heater is filling, open several hot water
faucets to allow air to escape from the water system. When a steady stream
of water flows through the faucets, close them and check all water
connections for possible leaks. NEVER OPERATE THE WATER HEATER
WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER.

13

Installation (Water Connections) continued-

WARNING
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local codes,
but not less than a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment or materials as
meeting the requirements of the Standard for Relief Valves and Automatic
Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22 or the
Standard CAN1-4.4. Temperature and Pressure and the Standard CAN14.4, Temperature, Pressure, Temperature and Pressure Relief Valves and
Vacuum Relief Valves. The combination temperature and pressure relief
valve shall be marked with a maximum set pressure not to exceed the
maximum working pressure of the water heater. The combination
temperature and pressure relief valve shall also have an hourly rated
temperature steam BTU discharge capacity not less than the hourly rating
of the water heater.
Install the combination temperature and pressure relief valve into the
opening provided and marked for this purpose on the water heater.
Note: Some models may already be equipped or supplied with a
combination temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve complies with local
codes. If the combination temperature and pressure relief valve does not
comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination
temperature and pressure relief valve will exit within 6 inches (15.2 cm)
above, or any distance below the structural floor and cannot contact any
live electrical part. The discharge line is to be installed to allow for
complete drainage of both the combination temperature and pressure relief
valve and the discharge line. The discharge opening must not be
subjected to blockage or freezing. DO NOT thread, plug or cap the
discharge line. It is recommended that a minimum clearance of 4 inches
(10.2 cm) be provided on the side of the water heater for servicing and
maintenance of the combination temperature and pressure relief valve.
Do not place a valve between the combination temperature and pressure
relief valve and the tank.

14

Installation (Water Connections) continued-

WARNING
Hydrogen gas can be produced in an operating water heater that has not
had water drawn from the tank for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable. To prevent the
possibility of injury under these conditions, we recommend the hot water
faucet to be open for several minutes at the kitchen sink before you use
any electrical appliance, which is connected to the hot water system. If
hydrogen is present, there will be an unusual sound such as air escaping
through the pipes as hot water begins to flow. Do not smoke or have
open flame near the faucet at the time it is open.
This water heater can deliver scalding temperature water at any faucet in the
system. Be careful whenever using hot water to avoid scalding injury. Certain
appliances such as dishwashers and automatic clothes washers may require
increased temperature water. By setting the thermostat on this water heater
to obtain the increased temperature water required by these appliances, the
potential for scald injury increases. To protect against injury, you should
install an ASSE approved mixing valve in the water system. This valve will
reduce point of discharge temperature by mixing cold and hot water in branch
supply lines. Such valves are available from the manufacturer of this water
heater or a local plumbing supplier. Please consult with a plumbing
professional.
Water temperature over 125F
(52C) can cause severe burns
instantly or death from scalds.
Children, disabled and elderly
are at highest risk of being
scalded.
Review this instruction manual
before setting temperature
at water heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available.

APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS


120F (49C)
More than 5 minutes
125F (52C)
1 to 2 minutes
130F (54C)
About 30 seconds
135F (57C)
About 10 seconds
140F (60C)
Less than 5 seconds
145F (63C)
Less than 3 seconds
150F (66C)
About 1 seconds
155F (68C)
About 1 second
15

Gas Connections
The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI
Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code
(Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).
The minimum permissible gas supply pressure for the purpose of input adjustment is 1 inch
(0.25 kPa) water column above the operating manifold pressure. See the rating plate and
gas valve for the manifold pressure and gas type. The maximum permissible gas supply
pressure is 14 inches (3.5 kPa) water column for natural gas and liquefied petroleum
gases/propane gas.
1.

Connect this water heater only to the type of gas (Natural or Propane gas) as shown on
the rating plate. Use clean black iron pipe or equivalent material approved by local
codes and ordinances. (Dirt and scale from the pipe can enter the gas valve and cause
it to malfunction). The inlet gas line must have a minimum length of 3 inches (7.6 cm)
drip leg (sediment trap) installed as close to the water heaters gas valve as possible.
A ground joint union must be installed as close to the water heater as possible in the
gas supply line feeding the water heater to permit servicing of the water heater.
Compounds used on the threaded joints of the gas piping must be resistant to the
action of liquefied petroleum gases/propane gas. DO NOT apply pipe dope to the gas
valve inlet and make certain that no pipe dope has become lodged in the inlet screen of
the gas valve. Extreme care must be taken to ensure no pipe dope enters the gas
valve. Avoid excessive torque when tightening the gas supply line to the gas valve.
Excessive torque may result in cracking of the gas valve housing and could create a
gas leak. When tightening gas supply line to L.P. control, it is recommended to hold
the inlet body of the control securely with an adequate wrench. The suggested
maximum torque is 31.5 ft. lbs. (4.4 kg-m).

WARNING
The manufacturer of this water heater will not be liable for any damage or injury
caused as a result of a cracked gas inlet as a result of excessive torque.
2.

3.

This water heater and its gas connection must be leak tested before placing the water
heater in operation. Check for gas leaks with a soap and water solution and a brush or
a commercial leak detector fluid. NEVER USE A MATCH OR OPEN FLAME FOR
TESTING!
While checking for leaks care must be taken to prevent solution from
contacting the electrical connections at the control. If electrical connections at the
control become wet, they must be thoroughly dried before attempting to operate the
water heater.

CAUTION
The water heater and individual shutoff valve must be disconnected from the gas supply
piping system during any pressure testing of the system at test pressures in excess of psi
(3.5 kPa). The water heater must be isolated from the gas supply piping system by closing its
manual shutoff valve during any pressure testing of the gas supply system at test pressures
equal to or less than psi (3.5 kPa). The supply line must be capped when not connected to
the water heater.

WARNING
The gas inlet pressure to the gas control must never exceed 14 inches of water column (
psi) (3.5 kPa). The gas supply system and any pressure regulating device in the gas line must
be specified, inspected and adjusted to assure a gas supply pressure of psi (3.5 kPa) or
less. Failure to do so may result in serious injury or death.

16

GENERAL OPERATION

Water heaters are heat producing appliances. To avoid damage or injury there shall
be no materials stored against the water heater or vent-air intake system, and proper
care shall be taken to avoid unnecessary contact (especially by children) with the
water heater and vent-air intake system. UNDER NO CIRCUMSTANCES SHALL
FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED
OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE
SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE
WATER HEATER OR VENT-AIR INTAKE SYSTEM.
TO FILL THE WATER HEATER
1. Close the water heater drain valve by turning the knob clockwise
.
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is filled.
Close the faucets and check for water leaks at the water heater drain valve,
combination temperature and pressure relief valve and the hot and cold water
connections.
TO DRAIN THE WATER HEATER
Should it become necessary to completely drain the water heater, make sure you follow
the steps below:
1. Rotate the thermostat dial clockwise
to the lowest possible position.
2. Rotate and partially depress gas control knob clockwise
to the OFF
position.
3. Shut off the gas supply to the water heater.
4. Close the cold water supply shut-off valve.
5. Open the drain valve on the water heater by turning the knob counter-clockwise
. The drain valve has threads on the end that will allow the connection of a
standard hose coupling.
6. Open a hot water faucet to allow air to enter the system.
To refill the water heater, refer to To Fill the Water Heater.

WARNING
Wait at least 2 minutes after this control is pressurized with gas before attempting to
light pilot and/or push igniter button. Failure to do so may result in serious injury.

17

Lighting and Shutdown Instructions-White Rodgers and Robertshaw gas


control.

18

Lighting and Shutdown Instructions-Honeywell gas control.

19

THERMOSTAT ADJUSTMENT - White Rodgers gas control.

160F Control

180F Control

Figure 2
The thermostat dial is set to its lowest temperature setting when shipped from the factory.
Remember that lower temperature settings are more energy efficient. Adjust the
temperature by turning the thermostat dial. It is suggested that the starting point setting not be
greater than the

or

mark on the thermostat dial (approximately 120F [48.9C]) as

indicated above. Rotate the thermostat dial clockwise

to decrease the temperature

setting. Rotate the thermostat dial counter-clockwise


to increase the temperature
setting. Adjust the dial until the minimum acceptable temperature is achieved (See figure 2
above for approximate temperature settings).

Robertshaw gas control.

160F Control

180F Control

Figure 3
The thermostat dial is set to its lowest temperature setting when shipped from the factory.
Remember that lower temperature settings are more energy efficient. Adjust the
temperature by turning the thermostat dial. It is suggested that the starting point setting not be
greater than the mark on the thermostat dial (approximately 120F [48.9C]) as indicated
above. Rotate the thermostat dial counter-clockwise

to decrease the temperature

setting. Rotate the thermostat dial clockwise


to increase the temperature setting.
Adjust the dial until the minimum acceptable temperature is achieved (See figure 3 above for
approximate temperature settings).

20

THERMOSTAT ADJUSTMENT - Honeywell gas control

RED
WIRE

WHITE
WIRE

160F (71.1C) Control

Figure 4
The thermostat dial is set to its lowest temperature setting when shipped from the factory.
Remember that lower temperature settings are more energy efficient. Adjust the
temperature by turning the thermostat dial. It is suggested that the starting point setting not be
greater than the HOT mark on the thermostat dial (approximately 120F [48.9C]) as
indicated above. Rotate the thermostat dial counter-clockwise

to decrease the

temperature setting. Rotate the thermostat dial clockwise


to increase the
temperature setting. Adjust the dial until the minimum acceptable temperature is achieved
(See figure 4 above for approximate temperature settings).

RED
WIRE

WHITE
WIRE

180F (82.2C) Control

Figure 5
The thermostat dial is set to its lowest temperature setting when shipped from the factory.
Remember that lower temperature settings are more energy efficient. Adjust the
temperature by turning the thermostat dial. It is suggested that the starting point setting not be
greater than the HOT mark on the thermostat dial (approximately 120F [48.9C]) as
indicated above. Rotate the thermostat dial counter-clockwise

to decrease the

temperature setting. Rotate the thermostat dial clockwise


to increase the
temperature setting. Adjust the dial until the minimum acceptable temperature is achieved
(See figure 5 above for approximate temperature settings).

21

General Operation continued-

WARNING
Hotter water increases the risk of scald injury. Scalding may occur within 5
seconds at a temperature setting of 140F (60C). To protect against hot water
injury, install an ASSE approved mixing valve in the water system. This valve
will reduce point of discharge temperature by mixing cold and hot water in
branch water lines. A licensed plumbing professional or local plumbing
authority should be consulted.
Note: This water heater is equipped with an energy cut out device to prevent
overheating. Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance and call a qualified service
technician.
Note: Whenever the water heater is filled with cold water, condensate will
form on the cool tank surface and drops of water will fall on the hot burner and
combustion chamber surfaces producing a sizzling noise. Condensation is
normal and does not indicate a leak. It will disappear when the tank becomes
heated.

BURNER FLAME CHECKS


Steel Burner: These models are equipped with self adjusting air mixture and
do not have an adjustable air shutter (See Figure 6). At periodic intervals, a
visual check of the main burner and pilot flames should be made to determine
if they are burning properly. The main burner flame should light smoothly
from the pilot.

Figure 6
WARNING
Do not run out of propane gas. Damage to the water heater may occur.

22

MAINTENANCE

WARNING
Water heaters are heat producing appliances. To avoid damage or injury there
shall be no materials stored against the water heater or vent-air intake system, and
proper care shall be taken to avoid unnecessary contact (especially by children)
with the water heater and vent-air intake system. UNDER NO CIRCUMSTANCES
SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR
INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD
REACH THE WATER HEATER OR VENT-AIR INTAKE SYSTEM.

IMPORTANT
The water heater should be inspected at a minimum annually by a qualified
service technician for damaged components and/or joints not sealed. DO NOT
operate this water heater if any part is found damaged or if any joint is found
not sealed.
The following maintenance should be performed by a qualified service technician at the
minimum periodic intervals suggested below. In some installations, the maintenance
interval may be more frequent depending on the amount of use and the operating
conditions of the water heater. Regular inspection and maintenance of the water
heater and vent-air intake system will help to insure safe and reliable operation.
1.

Annually check the operation of the thermostat.

2.

The flow of combustion and ventilation air MUST NOT be restricted. Make sure
slots in jacket are open and unobstructed. Clear jacket slot openings of any dirt,
dust, or other restrictions. WARNING! The ventilation air system may be HOT.

3.

At all times keep the water heater area clear and free from combustible materials,
gasoline and other flammable vapors and liquids.

4.

Bi-annually conduct a visual check of the main and pilot burner flames to
determine that they are burning properly. See Burner Flame Check section of this
installation and operation manual. If sooting or other burner anomalies are
evident, shut down the water heater by turning off the gas per the instructions
listed in this manual or as listed on the water heater.

5.

Annually remove the inner door and main burner assembly to clean orifices and
related parts of any dirt or other foreign material. Inspect the burner ports for
obstructions or debris and clean with a wire brush as needed. Wire brush and/or
vacuum clean the combustion chamber as needed to remove scale deposits and
debris. NOTE: It is imperative for proper operation of the water heater that the
inner door be replaced in the original location, making certain the resetable
thermal switch is properly connected to the gas control wire leads provided.

23

Maintenance continued-

WARNING
Do not operate water heater with jumpered, altered, loosely
tightened or absent controls and/or components.
Do not operate water heater with replacement controls and/or
components, which are not exact duplicates or original
equipment.
Thoroughly inspect and replace, (as needed) burner inner door
gasket and/or sight window gasket any time burner inner door is
removed or disturbed.
Replace water heater if involved in flammable vapors incident.

WARNING
When lifting lever of the combination temperature and pressure
relief valve, hot water will be released under pressure. Be careful
that any released water does not result in bodily injury or
property damage.
6. At least once a year, check the combination temperature and pressure
relief valve to insure that the valve has not become encrusted with lime.
Lift the lever at the top of the valve several times until the valve seats
properly without leaking and operates freely.

WARNING
Do not run out of propane gas. Damage to the water heater may occur.

WARNING
THIS WATER MAY BE HOT.
7. Monthly drain off a gallon of water to remove silt and sediment.
8. If the combination temperature and pressure relief valve on the appliance
discharges periodically, this may be due to thermal expansion in a closed
water supply system. Contact the water supplier or local plumbing
inspector on how to correct this situation. Do not plug the combination
temperature and pressure relief valve outlet.
9. A combination sacrificial anode rod/hot water outlet nipple has been
installed to extend tank life. The anode rod should be inspected
periodically (every 2 years) and replaced when necessary to prolong tank
life. Water conditions in your area will influence the time interval for
inspection and replacement of the anode rod. Contact the plumbing
professional who installed the water heater or the manufacturer listed on
the rating plate for anode replacement information. The use of a water
24

Maintenance continued-

softener may increase the speed of anode consumption. More frequent


inspection of the anode is needed when using softened (or phosphate
treated) water.
10. The vent system must be inspected at least once a year to ensure against
leakage of exhaust products.

CAUTION
FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION
GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A
QUALIFIED SERVICE TECHNICIAN.
Contact your supplier or plumbing professional for replacement parts or
contact the company at the address given on the rating plate of the water
heater.
Provide the part name, model and serial numbers of the water heater when
ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH
OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.
Manufactured under one or more of the following U.S. Patents: RE.34,534;
B1 5,341,770; 4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983;
4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519;
5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952;
5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,142,216;
6,395,280; 6,684,821; 7,063,132; 7,007,748
Other U.S. and Foreign patent applications pending. Current Canadian Patents:
1,272,914; 1,280,043; 1,289,832; 2,045,862; 2,092,105; 2,107,012; 2,108,186;
2,112,515

Complete the following information and retain for future reference:


Model No: ___________________________________________________
Serial No: ___________________________________________________
Service Phone
Days: __________________ Nights: _____________________________
Address:_____________________________________________________
Supplier: ____________________________________________________
Supplier Phone No: ____________________________________________
25

TROUBLESHOOTING CHART
LED Status

Control Status

Probable Cause
1.

Gas valve is functioning


normally
Gas valve is not powered.
Light pilot

None (LED not on or


flashing)

Millivolt power is not


present. Light pilot.

One flash and three


second pause.

Gas valve is powered and waiting


If set point knob is in
"PILOT" position then pilot for the set point knob to be turned
to a water temperature setting. If
flame is detected. (no
the set point knob is at desired
faults).
setting the thermostat is satisfied.

2.

LED strobe (two quick


Thermostat calling for heat
flashes) and three second
Water heater operating normally.
(no
faults)
pause
Set point knob was recently turned
to "OFF" position. Wait until LED
goes out before attempting to
relight

LED on continuously.

Set point knob has been


recently turned to the
"OFF" position.

Two flashes and three


second pause.

Weak pilot flame detected. 1.


2.
System will reset when
pilot flame is sufficient.

Three flashes and three


second pause.

Insufficient water heating.


System will reset.

2.

Temperature sensor out of


calibration.
Possible short.

Four flashes and three


second pause.

1.
Excessive tank
temperature. System must
2.
be reset.

Temperature sensor out of


calibration.
Faulty gas valve.

1.

1.
2.
3.
4.
Five flashes and three
second pause.

Temperature Sensor fault.


5.

6.

26

Unstable pilot.
Pilot tube blocked or
restricted.

Damage to the temperature


wire.
Temperature sensor
resistance out of range.
Replace temperature sensor.
If temperature sensor
replacement does not correct
the problem; Verify control is
not wet or physically damaged
Turn set point knob to "OFF"
position. Turn set point knob
to "PILOT" position and light
pilot.
Replace gas valve if five flash
error persists.

TROUBLESHOOTING CHART (CONTINUED)


LED Status
Six flashes and three
second pause.

Control Status
Water leak detected by
accessory module (some
models).

Probable Cause
Excessive amount of water in drain
pan/water dam.
1.

Seven flashes and three


second pause.

Eight flashes and three


second pause

Verify control is not wet or


physically damaged.
2. Turn set point knob to "OFF"
position. Turn set point knob
Gas valve electronic fault
to "PILOT" position and light
detected.
pilot.
3. Replace gas valve if seven
flash error persists.
1. Pilot valve stuck in open
position
2. Turn set point knob to "OFF"
position. Turn set point knob to
False pilot flame present.
"PILOT" position and light pilot.
3. Replace gas valve if eight flash
error persists.

27

INSTALLATION FOR POTABLE WATER

Figure 7

28

PARTS LIST DRAWING

29

PARTS LIST

PART NAME AND DESCRIPTION


1. Draft Diverter

14. Drain Valve

2. Jacket Head Pan

15. Piezo Igniter

3. Jacket

16. Gas Control Valve

4. Outer Door

17. Steel Burner

5. Magnesium AnodeHot Water Outlet

18. Orifice

6. Flue Baffle Assembly

19. Gas Feedline to Burner

7. Dip TubeCold Water Inlet

20. Gas Feedline to Pilot

8. Temperature and Pressure Relief Valve

21. Thermocouple/Thermopile Lead

9. Glass Lined Tank

22. Piezo Igniter Lead

10. Combustion Chamber Assembly

23. Pilot Assembly

11. Jacket Base Pan


12. Inner Door Gasket
13. Inner Door Assembly
13A. High temperature limit switch

30

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:


GAS WATER HEATERS
SUITABLE FOR WATER (POTABLE) HEATING AND SPACE
HEATING
1. All piping components connected to this water heater for space heating
applications must be suitable for use with potable water. In
Massachusetts, space heating piping length must not exceed 50 feet.
2. Toxic chemicals, such as those used for boiler treatment, must not be
introduced into potable water used for space heating.
3. This water heater must not be connected to an existing heating system
or component(s) previously used with a non-potable water heating
appliance.
4. When the system requires water for space heating at temperatures higher
than required for other means, such as an ASSE approved mixing valve
must be installed to temper the water for those uses in order to reduce the
scald hazard potential.
Please refer to figure 8 and figure 9 for suggested piping arrangements.

Figure 8

Figure 9

31

NOTES

32